Product Line: Desublimators

ALWAYS ONE STEP AHEAD

EXPERTS IN HEAT EXCHANGE – SINCE 1920

KELVION – A TRIBUTE TO LORD KELVIN (1824 - 1907)

OUR LOGO – INSPIRED FROM THE SCHEMATIC FOR HEAT EXCHANGER

67 BRANCHES AND SALES PARTNERS WORLDWIDE

YOUR MARKETS ARE OUR MARKETS

KELVION HAS A LONG HISTORY

2015

2014

2010

1999

1920

5,000 EMPLOYEES WORLDWIDE

Welcome to Kelvion! Where Heat Exchange is our Business.We are one of the leading global manufacturers of heat exchangers and have been providing solutions for almost every industrial application imaginable since the 1920s, specializing in customized solutions suitable for extreme environ- mental conditions - as of 2015 under the name of Kelvion.

With one of the most extensive selections of heat exchangers in the world, we are a well-known partner in many industries, including transportation, energy, oil and gas, the heavy industry, chemical and marine as well as sugar, food and beverage and the HVAC and refrigeration technology sector. Our products include Compact Fin Heat Exchangers, Plate Heat Exchangers, Single Tube Heat Exchangers, Transformer Cooling Systems, Cooling Towers and Shell & Tube Heat Exchangers.

Our many years of experience and in-depth expertise have made us specialists in this field. Our heat exchangers are designed specifically to meet the needs of the respective machine or equipment system, ensuring outstanding energy efficiency and reliability in any market segment. This gives our customers a cutting-edge over their competitors while also reducing operating costs over the long term.

As your heat exchange partner, we understand that outstanding and reliable after-sales services are critical for you, our customer, and we work alongside with you in close partnership supporting you throughout the full life cycle of your plant and equipment to ensure lasting business success.

Kelvion – Experts in Heat Exchange.

Chemicals

With the new name, the former GEA Heat Exchangers is writing its own history as Kelvion.

GEA sells the Heat Exchangers Segment to Triton.

Reorganization of GEA‘s 9 Divisions into techno- logically distinct Segments. The largest segment is the Heat Exchangers Segment.

In April 1999, GEA was acquired by mg technologies AG

Foundation of GEA in Bochum by Otto Happel sen. (Born 1882)

Refrigeration

Sugar

HeavyIndustry

Oil & Gas

Food & Beverages

Marine

Transportation

HVAC

Power

Lord Kelvin formulated the laws of thermodynamics and absolute units of temperature are stated in kelvin, in his honor.

We invest in Quality and Sustainability

60 YEARS OF RESEARCH & DEVELOPMENT

KELVION INNOVATIONS

⊲ Innovation through continuous development in cooperation with universities and institutes

⊲ Continuous development driven by customers’ experiences

⊲ Optimum use of surface area for highly-efficient product separation

⊲ Long lifetime due to flexible design for cyclic operation

⊲ Lighter weight for reducing energy consumption

In 1954 Kelvion engineers invented the first desublimator, called the Switch Condenser, for the phthalic anhydride (PA) process. Today the technology can be found in most PA plants around the world.

Over the last 65 years we have continued to refine and further develop our products, in co-operation with our customers, making us the global market leader in desublimation technology.

The latest generation Switch Condenser was introduced in 2012, while Mini Desublimator, our smallest model, has been a popular choice since 1982 for protecting the vacuum system of the distillation in the PA process, as well as many other applications.

Our engineers not only focus on thermodynamics and heat engineering, but also work closely with our customers to provide a desublimator that will integrate fully with their specific process-engineering requirements.

With their intimate knowledge of manufacturing and applications, Kelvion experts analyse production environments and processes. They then develop recommendations and help to implement them. Our approach is holistic, but the solution is specific and individual.

Our extensive manufacturing and welding engineering know-how enables us to offer all weldable materials when designing the unit. Our range of services is rounded off by support during plant start-up and optimisation in day-to-day operation.

log p / T DIAGRAM: PARTIAL PRESSURE AS FUNCTION OF TEMPERATURE

Desublimation is the direct phase change of a substance from a gas to a solid, without an intermediate liquid state. This phenomenon naturally occurs in the formation of hoarfrost when water vapour from the ambient air freezes on contact with cold surfaces as ice crystals. Frost on the window in winter is a familiar example. Another is the frost formation in home freezers.

Kelvion engineers reproduced this process in a desublimator to separate substances from gas mixtures.

The log p/T diagram shows that desublimation is separate from condensation. Whereas water from the ambient air condenses above the triple point, the water below the triple point can only desublimate from the gas phase. As well as direct desublimation just below the triple point, indirect desublimation is also possible. The result is crystallization, but indirectly via previous condensation. The gaseous substance first condenses, but then freezes immediately on the cold surface – in nature this manifests as freezing rain.

DESUBLIMATION PRINCIPLE

DESUBLIMATOR OPERATION

STEP 1

Gas mixture enters the desublimator.

STEP 2

The gas mixture flows through cooled lamellas/fins where the part to be separated desublima-tes either around or below its triple point, and adheres to the cold surface in crystalline form.

STEP 3

The crystallized product is melted off as soon as the desublimator is fully loaded. Using a minimum of two desublimators allows a continuous process.

PHASE CHANGES

⊲ Condensation: phase change above the triple-point e. g. rain, dew formation

⊲ Indirect desublimation: phase change just above the triple-point e. g. freezing rain, freezing moisture on cold surfaces

⊲ Direct desublimation: phase change below the triple-point e. g. snowfall, crystallization on cold surfaces

GOOD TO KNOW

⊲ Desublimators are not “regular” heat exchangers.

⊲ The purpose of desublimators is material separation through phase change.

⊲ Desublimation is a thermodynamic material separating process.

⊲ Desublimation can be an attractive alternative to adsorption, absorption or cyclon separation methods.

log p

Condensation

IndirectDesublimation

Triple-point

DirectDesublimation

T

Solid phase Liquid phase

Gaseous phase

OUR SOLUTIONS

approx. 80 %

... HEAT EXCHANGERS

40 - 45 %

... POWER PLANTS

approx. 99.5 %

... DESUBLIMATORS

approx. 98 %

... FILTERS / DEMISTERS

EFFICIENCY OF...

WHY TO USE KELVION DESUBLIMATORS

Technical DesublimatonDesublimation is a thermodynamic process for separating product from a gas stream and is an alternative to adsorption and absorption. The separation is achieved by cooling and heating in batch-operation. It is used, for example, in chemical and pharmaceutical processes, to secure vacuum pumps or for tank venting. The separated component can be an invaluable raw material or may be hazardous for the environment.

Kelvion desublimators are available in a range of vessel sizes, materials, certificates and tests to support customer requirements worldwide.

Desublimator TechnologyThe design philosophy of our desublimators is the optimal use of the entire installed surface for collecting substances. For that reason, we have introduced at least three sections with different designs and functions.

For example, the desublimator for the PA process, called a Switch Condenser has high density, high yield and high efficiency sections. The high density section is located next to the gas inlet to collect PA in a very compact form. The high yield section in the middle of the unit is not only for PA collecting but also for gas cooling. Finally, the high efficiency section next to the gas outlet is designed mainly for gas cooling. In addition, it has a special filter function for PA needles, which guarantees the very high efficiency of our Switch Condensers.

While the Switch Condenser is a tailor-made solution for the PA process, the Mini Desublimator Mini Desublimator is well established for many other applications, using the same design philosophy.

Highest separation effciency of components from gas-streams at optimum product purity.

Innovative and advanced product due to our co-operation with international universities and institutes, as well as with industries

Low energy consumption achieved through optimized equipment design

Highest ecological compatibility by avoiding solvents

Mini Desublimator Mini Desublimator Switch Condenser

DESIGN TEMPERATURE

⊲ -150 °C TO 350°C

GAS FLOW

⊲ 5 - 500 KG / H

DESIGN PRESSURE

⊲ VACUUM UP TO 50 BAR

Product separation in chemical & pharmaceutical

processes

Environmental protection

Protection of vacuum systems

Recovery of valuable (raw) materials

Tank venting

Typical substances that can be separated by desublimation in Mini Desublimator:

DESIGN DATA

⊲ TÜV NORD ⊲ TÜV Rhineland ⊲ TÜV Austria ⊲ Det Norske Veritas ⊲ Class NK

⊲ Lloyd’s Register of Shipping ⊲ Bureau Veritas ⊲ American Bureau

of Shipping ⊲ Germanischer Lloyd

⊲ Urzad Dozoru Technicznego ⊲ Inspection and Quarantine

of the PRCh ⊲ Gost – RT ⊲ U-Stamp acc. ASME Code

Mini Desublimator

THE BIG SMALLApplications

Typical substances that can be separated by desublimation:In the Mini Desublimator unit the gas mixture comes into contact with cooled lammaellas/fins. Here that part of the gas mixture to be separated desublimates either around or below its triple point and adheres to the cold surface in crystalline form. The Mini Desublimator unit is split into several sections to achieve an optimum distribution of the product inside the desublimator. This special design feature ensures the highest separation efficiencies and longest loading times.

A range of lamella/fin designs are available for optimum utilization of the heat exchanger surface – and the sectors are adapted individually to each process requirement to achieve superior separation effici-ency of over 99.5 percent. The crystalized product is melted off as soon as the desublimator is fully loaded. The heating medium flows through the same channels as the cooling medium. A continuous process is achieved by using a minimum of two Mini Desublimators.

Mini Desublimator comes in standard sizes, as well as a wide range of tailored design configurations and internal fittings. Thanks to its compact design the unit does not take up too much space. Mini Desublimator is available in all weldable materials. For operational safety and to reduce the risk of leaks, there is no direct welding between the gas and cooling/heating sides. Also, the number of welds is minimized. Design, manufacturing and testing to the highest international standards prove Mini Desublimator‘s reliability.

INTERNATIONAL CERTIFICATION

BENEFITS

⊲ Clean process: no chemicals or water needed ⊲ Excellent separation efficiency of 99.5 % ⊲ High product purity ⊲ Minimal space requirements due to compact design ⊲ No moving parts: low wear, high operational reliability,

virtually maintenance-free ⊲ Low energy consumption

POSSIBLE APPLICATIONS

Recovery of valuable (raw) materialsIn the chemical and pharmaceutical industries it is not unusual for valuable raw materials to be found in the production process. These may only be required as reaction intermediates, not for inclusion in the end product.

An example of this is iodine, which is a very expensive halogen. Iodine contained in gaseous substance streams desublimates even at room temperature. When used as an intermediate, it can be easily recovered in Kelvion desublimators.

In the production of polyphenylene sulfide (PPS) several desublimators are installed in certain process steps to separate the valuable iodine. Using desublimators, iodine can be almost completely recovered, making the continuous production process of PPS economically viable.

Protection of vacuum systemsA problem encountered in process engineering is when the vacuum generator draws in substances contained in the suction stream. These can desublimate in the inner part of the generator, causing blockages. To avoid this, desublimators can be used to clean the substances from the suction stream.

For example, in vacuum distillation two desublimators will clean the saturated suction gas from the distillation section. In this way, a continuous and safe process is guaranteed.

Product separation in processesWhen the PA process was established in 1954, in co-operation with chemical and pharmaceutical industry pioneers, Kelvion provided valuable support with the launch of its first desublimators. Since then, our thermodynamic separation technology has provided a reliable alternative, with significant advantages, to the traditional separation methods of adsorption, absorption and cyclones.

In the PA process ambient air is enriched with a feedstock, which reacts to generate the PA. This is then separated from the reaction gas stream and used commercially as an industrial chemical and raw material.

The Kelvion desublimators can handle large amounts of gas and therefore separate a significant amount of PA – at the highest efficiency in the industry of 99.5% minimum. Today the PA process remains the main application for our desublimators in the chemical industry, which are installed in most PA plants worldwide.

In recent years we have successfully introduced this technology into other processes. For a continuous process at least two desublimators have to be installed. The PA process commonly requires four desublimators per production line.

Environmental protection and tank ventingAnother application for the Kelvion desublimator is cleaning polluted waste gas streams, for example, venting of industrial fuel or storage tanks. The vent gases leave the tanks as a mixture of inert gas saturated with the stored substance. The desublimator acts as a vent cooler to reduce the amount of substances that can be desublimated escaping into the environment. The waste gas is reliably cleaned in the desublimator by separating the substance enriched in the inert gas. In this application it is generally sufficient to install only one desublimator directly on top of the tank.

Desublimation offers the following advantages over other substance separation processes, such as washing with solvents:

⊲ low operational cost ⊲ environmentally friendly ⊲ no solvents to be disposed of ⊲ high product purity ⊲ high separation rates

GAS FLOW

⊲ MAX. 40,000 NM³/H

CAPACITY

⊲ MAX. 10,000 KG PA/CYCLE

EFFICIENCY

⊲ MIN. 99.5 %

O-XYLENE LOADING

⊲ 100 G/NM³ AIR & HIGHER

BENEFITS

⊲ Highest efficiency/minimum PA loss ⊲ Low weight ⊲ Low operating cost ⊲ Low energy consumption ⊲ High reliability ⊲ Minimized risk of fatigue failures ⊲ Long lifetime ⊲ Maintenance friendly

Gas in

High efficiency section

High yield section

High density section

Oil in

Oil out

Gas out

PA

Switch Condenser

THINK BIG

Since the invention of the Switch Condenser in 1954, Kelvion has delivered more than 1,500 units globally for PA processes. We have continuously developed the mechanical as well as the process design of our Switch Condensers. In particular, we have adapted the specially designed fin tube system of rectangular fins to meet the latest PA process requirement of increasing feedstock loading of the air.

The design philosophy behind our Switch Condensers is the optimal use of the entire surface for collecting PA, to ensure eco-nomical loading times. For that reason, we have introduced three sections of fin tube systems with different designs and functions.

The main task of the high density section is collecting PA in a very compact form. Next, there is a high yield section, which also collects PA and cools gas. Finally, the high efficiency section has a special filter function for PA needles. This guarantees the very high efficiency rate of Kelvion switch condensers.

Our engineering excellence has convinced our customers worldwide, who have confirmed our technological advantages in their processes and daily operation. As a result, Kelvion is the undisputed world market leader in desublimator technology.

Based on our extensive knowledge of the PA process, Kelvion engineers have developed further valuable solutions for this process. In particular, the GasKat (postreactor) and Precondenser (partial PA condenser), both of which are standard in a modern PA plant.

DESIGN DATA

C6H4(CO)2O

Phthalic anhydride is an important industrial chemical and raw material for manufacturing plasticizers for plastics, resins and polyols, among others. It was the first anhydride of a dicarboxylic acid to be used commercially.

In the PA process, o-Xylene or naphthalene are oxidized in a catalytic reaction to form phthalic anhydride. Besides the Switch Condenser, two other Kelvion technologies are an established part of the process:

⊲ the gas stream is cooled down in the Kelvion safety gas cooler with or without integrated postreactor, the Kelvion GasKat,

⊲ the PA is separated from the reaction gas in Kelvion’s PA separation system, which consists of the Kelvion preconden-ser (where PA condenses in liquid form) and normally four Switch Condensers (where PA desublimates in solid form).

PA Process

PHTHALIC ANHYDRIDE PRODUCTION

KELVION AIR COOLED CONDENSER

KELVION SWITCH CONDENSER 3X

KELVIONAIR FIN COOLER

KELVION AIR PRE HEATER

KELVION MINI DESUBLIMATOR

REACTOR

KELVION GAS COOLER

KELVION PRE CONDENSER

AIR COOLED CONDENSER (ACC)

The PA process is highly exothermic. In many high-loading PA plants, this surplus of energy is used for power generation in a turbine. For condensing the steam downstream of the turbine, Kelvion offers Air Cooled Condensers.

AIR FIN COOLER (AFC)

The Switch Condenser requires a cold oil circuit to operate effectively. The oil has to be re-cooled downstream to keep it at the correct temperature. An Air Fin Cooler is the tried and tested technology for this task.

PA Process

KELVION SOLUTIONS EXPLAINED

SAFETY GAS COOLER/ GASKAT

Downstream of the reactor, the gas must be cooled down to allow the separation of PA. The Kelvion GasKat, which combines a safety gas cooler with a post-reactor in one casing, is the ideal solution. The gas is cooled by the combination of superheating the steam, water evaporation and/or heating of boiler feed-wa-ter. GasKat has removable bundles (screwed into the casing) for easy maintenance and laser welded fins – no added materials to the welding seam. The use of finned tubes provides a very compact unit.

SWITCH CONDENSER

The Kelvion Switch Condenser is an essential part of any PA plant. Its special process and mechanical design guarantees the highest separation efficiency and a long operational lifetime. Because of its relatively low weight, Kelvion’s SWC is low on energy con-sumption.

PRE CONDENSER

Kelvion developed the Pre-condenser in 1990 specifically to enable the continuous separation of PA in high loading PA-plants, where concentrations are way above the triple point. The Pre-condenser separates the PA from the gas in liquid form, before the gas enters the Switch Condensers.

AIR PREHEATER

The Kelvion Air Pre-heater plays an important role in heating the ambient air to approximately 200°C, to allow the reaction to take place. This safety finned-tube heat exchanger is a compact unit. It comes with removable bundles (screwed into the casing) for easy maintenance.

MINI DESUBLIMATOR

The Mini Desublimator has two main applications in the PA pro-cess. Firstly, in distilling the crude PA, where vacuum is required. The Mini-Desublimator protects the vacuum generator against blockages in the vacuum system. The second application is for venting tanks of PA or naphthalene.

START-UP SERVICESWe ensure that our products are deliveredsafely and are fully validated to give arobust and reliable performance over aslong a life cycle as possible.

⊲ Design, manufacturing, delivery, erection, commissioning of revamped Desublimator

⊲ Supervision of construction on site ⊲ Commissioning assistance ⊲ Assistance to erection sub-contractor

INSPECTIONS AND MAINTENANCEThrough regular inspections andmaintenance, we help you to reducecosts, extend the lifetime of all yourKelvion products and to achieve a reliableperformance. This also helps you withbudget planning.

⊲ Preventive Inspections ⊲ Oil leaks ⊲ Gas leaks ⊲ Bent tubes ⊲ Deposits

⊲ Corrosion analysis of fins

UPGRADES AND REPLACEMENTSWe replace components to keep our Desublimators running smoothly and to preventdowntime. Where parts have become obsolete, we will suggest an upgrade.

⊲ Bundle repair ⊲ Casing revamp ⊲ Revamp process design

⊲ Postreactor revamp ⊲ Desublimator revamp

REPAIRS AND OVERHAULSWe understand that unscheduled downtimecan be disastrous. That is why ourtrained engineers are ready to respondquickly in an emergency. We will reviewand repair components while keepingany disruption to a minimum. Any overhaulwork is carried out in our service centersand conforms to the highest qualitystandards.

⊲ Supervisor ⊲ Site works ⊲ Repairs

CONSULTING AND TRAININGWould you like a consultancy service thattakes into account the special features ofyour process and were you feel that findingthe right solutions are more important thanclosing the deal quickly? Then you willfeelright at home with Kelvion. We will workclosely with you to develop the exact solutionthat is best tailored to your needs.

⊲ Site training ⊲ Analysis of operating data ⊲ Optimizing of general performance ⊲ Failure analysis

OUR SERVICE IN THREE WORDS: PEACE OF MIND

SPARE PARTS ANDSPARE PARTS SOLUTIONSEven the best equipment shows signs ofwear over time. We use only the highestquality spare parts, designed to match theexcellence of the originals. This ensuresthat the optimum interaction betweencomponents is maintained. By safeguardingthe original design we offer maximumsecurity of your investment.

⊲ Spare bundles ⊲ Spare finned tubes ⊲ Spare Gaskets ⊲ Spare Rupture Discs ⊲ Spare Bellows ⊲ Spare parts

TESTING AND MONITORINGHaving an understanding of the condition ofthe equipment allows you to secure reliableproduction, improve safety and energyefficiency and increase equipment lifetime.It can also help you to prevent breakdownsand prepare for the future.

⊲ CFD modelling ⊲ Process temperature analysis for:

⊲ Gas inlet ⊲ Gas outlet ⊲ Oil inlet ⊲ Oil outlet ⊲ Cycle times

Global production footprintGlobal sales and service

GLOBALLY ACTIVE AND STILL CLOSE BYNo matter where your market is, regardless of country, we are never far away. We are always happy to answer any questions you may have and meet your requirements. Even the largest, most successful project begins with an initial, profitable conversation. We look forward to hearing from you.

Just scan this QR code with your smartphone or visit our website at: www.kelvion.com – there you will find a highly competent contact in your immediate vicinity. ©

Kel

vion

• A

ll rig

hts

rese

rved

• Ve

rsio

n 01

• 12

/19

www.kelvion.com